4

Processing of Sweet Corn

Mariusz Szymanek
University of Life Sciences in Lublin
Poland
1. Introduction
1.1 Sweet corn kernel structure, chemical composition, and sensory qualities
Sweet corn cobs constituting raw material for processing must be characterized by the
highest quality of kernels. Kernel quality is defined not just by the chemical and sensory
properties, but also by the mechanical parameters of kernels. This appears to fully justify
joint consideration of all those properties. Sweet corn is probably a mutant of fodder corn
(Orowski, 2000). Significant differences between the two are related more to the genetics
than to the structure of the kernels. As emphasized by Salunkhe and Kadam (1998), the
structure of the kernels is strongly related to thegenetic modification and to ripeness.

Fig. 1. Schematic of longitudinal cross section of a sweet corn kernel: 1 pericarp, 2

endosperm, 3 germ, 4 pedicel, 5 aleurone layer, 6 tube cells, 7 epicarp, 8 mesocarp,
9 cross cells (Salunkhe and Kadam, 1998).
Sweet corn kernel is built of the pedicel, the pericarp, the germ, and the parenchyma (Fig. 1).
The pedicel is a hard and fibrous remnant of the tissue that joins the kernel to the cob core
(Szpaar and Dregiew, 1999). During kernel shearing, a part of the pedicel remains on the
kernel, which has a negative effect on its nutritional value. Kernel shape is described as
flattened and wedge-like, with the tip much broader than the base end by which the kernel
is attached to the cob core. The kernel is deep set on an abbreviated shoot (rachis) forming
the cob, and is covered with a thin pericarp. The pericarp is a component of the seed coat

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tissue and forms the outer layer of the kernel. The thickness of the layer determines the
kernel skin level of tenderness. This feature is important in the estimation of kernel quality
for processing. As compared to other varieties, sweet corn is characterized by lower
thickness of the epicarp, on average 25-30 m (Ito and Brewbaker, 1991). The epicarp is
composed of a single layer of pericarp, in the cavities of which single cells of the mesocarp
are located. It also includes one or two layers of cross-cells and one or more tube cells
adherent to the pericarp. The germ, located obliquely at the base of the kernel, is large and
constitutes about 15% of the volume or 11.5-14% of the weight of the kernel. Germ size,
however, is cultivar-related and may constitute 5% of the mass of the whole kernel
(Puangnak, 1998). In turn, the parenchyma is the largest element of the kernel. It is in the
parenchyma that the sugars, starch, and water-soluble polysaccharides are accumulated in.
In the phase of consumption ripeness, the consistency of kernels is soft, delicate, creamy,
and the taste is sweet and fragrant (Reyes and Varseveld, 1982). The kernel seed coat has
colours from pale yellow to orange, often also with a violet tint and shiny. In the genotype
of sweet corn, apart from the genotype of sweet corn, except gene su (sugary) gene
determining the sweet taste and tenderness of the kernel, also other genes have been
discovered, responsible for enhancing the sweetness and the taste and utility qualities the
gene se (sugary enhancement) and the gene sh2 (shrunken 2). Genetic combinations of the
genotypes su and sh2 helped in the creation of very sweet cultivars (Simonne et al., 1999). In
the phase of full ripeness, sweet corn has wrinkled kernels, almost completely filled with
vitreous parenchyma, mostly white or yellow in colour. The reserve substance of the
parenchyma is composed of amylodexstrins which are responsible for the sweet taste. The
kernel has a bulbous shape, oval, wedge-shaped or angular, a smooth or wrinkled surface,
and white, yellow, read or brownish colouring. It is enclosed in a cover formed from fused
pericarp and seed coat, beneath which there is a layer of aleurone cells, the parenchyma, and
the germ. From the moment of pollination till harvest the cob of sweet corn undergoes
numerous physical and chemical transformations which largely affect the taste and the
quality of kernels. The taste is especially strongly affected by the transformations of sugars
(Wong, 1994). With respect to the content of sugars, three types of sweet corn cultivars are
distinguished: normally sweet cultivars, type su (sugary), with sugar content of 4-6%,
cultivars with increased sugar content, type se (sugary enhancement) 6-8%, and very sweet
cultivars, type sh2 (shrunken 2) 8-12% (Warzecha, 2003). Apart from the content of sugars,
fresh mass of sweet corn kernels contains 2.1-4.5% of proteins, 3-20% of starch, 1.1-2.7% of
fats, 0.91.9% of cellulose, 912 mg of vitamin C, small amounts of vitamins A, B1, B2, PP,
and mineral components such as: sodium, potassium, magnesium, calcium, phosphorus,
iron, selenium, copper, nickel and chromium (Felczyski et. al., 1999; Lee and McCoon,
1981). The chemical composition of the kernels is related to the weather conditions, ripeness,
and method of storage (Salunkhe and Kadam, 1998). According to data from the USDA
(Hardenburg and Watada, 1986), the nutritional value of sweet corn kernels is related to the
content of water (72.7%) and to the total content of solid parts (27.3%). Solid parts include
hydrocarbons (81%), proteins (13%), lipids (3.5%), and others (2.5%). Starch is the dominant
hydrocarbon component. Sweet corn has the highest nutritional value in the phase of milk
ripeness. With progressing phase of ripeness, in the transition to the phase of wax ripeness
the content of sugars decreases, accompanied by an increase in the content of starch (Suk
and Sang, 1999). In 100 g of kernels there is about 3.03 g of saccharine, 0.34 g of glucose and

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0.31 g of fructose. The content of saccharine increases, and that of reducing sugars decreases
as the kernels reach the optimum ripeness . The content of proteins in the kernels decreases
from the surface towards the centre of the kernel. The content of proteins, free aminoacids,
water-soluble and insoluble hydrocarbons, increases up to the phase of wax ripeness, and
then gradually decreases (Azanza et. al., 1996). The amounts of the particular components in
various cultivars and in various phases of ripeness variable. In comparison to other cereals,
sweet corn is relatively rich in oil. Approximately 90% of the oil is accumulated in the germ.
Sweet corn is more tasty than other corn species, thanks to its high content of water-soluble
polysaccharides. That component imparts to the kernels their tender and creamy character.
The most important parameters that affect the sensory quality of the kernels include
sweetness, texture, and taste (Wong and Swiader, 1995). Sweetness depends on the content
of sugars, while texture depends on a number of factors, such as tenderness of the seed coat,
moisture, content of water-soluble polysaccharides. Taste, in turn, is frequently associated
with the content of DMS (dimethyl sulphide). Decrease in kernel quality related to loss of
taste and aroma after the harvest is a problem for the processing industry. The loss of taste
in fresh or frozen state of the kernels is caused by enzyme activity (Collins and Biles, 1996).
Fresh kernels are characterized by faint aroma or its total absence. Wade (1981) states that
cut kernels have three characteristic types of aroma. Two of these are similar to the aroma of
fresh green vegetables, and the third is described by that author as a methol-type aroma.
With progressing ripeness of sweet corn, the level of DMS in the kernels decreases, which is
a serious problem for the processing industry due to the related considerable loss of taste of
processed sweet corn products.
The consumption quality of fresh sweet corn largely depends on the content of sugars and
water-soluble hydrocarbons in the kernels (Evensen and Boyer, 1986). The quality of sweet
corn kernels can be determined in many ways. The basic discriminant of kernels for the
processing industry is kernel hardness and taste. One of the most important factors
determining the quality of kernels for processing is the use of cultivars characterized by
uniform ripening. The choice of cultivar affects not only the yield of kernels cut off cobs, but
also the taste quality of the kernels. Other quality factors include the colour, sweetness, and
tenderness of the kernel cover. With ripening, the cover becomes harder and harder. The
quality of sweet corn is correlated to the content of sugars. The transformation of sugars into
starch is also related to decreasing moisture content of the kernels.
1.2 Characterization of sweet corn varieties
The choice of variety is one of the more important factors the determine whether sweet corn
production is a success. Population (fixed) varieties have been largely replaced in cultivation
by hybrid (heterotic) varieties, created by man in the first half of the 20th century as new
forms of the crop plant. Hybrid varieties spread less, produce bigger and evenly ripening
cobs, and are higher yielding compared to the population varieties. They are characterized
by high sensory qualities and are suitable for direct consumption and for the processing
industry alike. They meet the requirements of the fruit and vegetable processing industry in
terms of having very delicate kernel skin and kernels easy to separate from the cobs in
whose mass the kernels constitute 3040%. Primary differences among the hybrid varieties
include the duration of their vegetation period, content of sugars, and suitability for various

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uses. The productive value of the varieties is determined primarily by their yield capacity
and the earliness of their ripening.
Producers involved in sweet corn growing for direct consumption are interested in
obtaining a large number of well kernelled cobs. Those producing sweet corn for industrial
processing expect a high yield of material suitable for processing. In terms of the length of
the vegetation period the following groups of corn varieties are distinguished:
-

early varieties (7080 days),

medium early varieties (8590 days),
late varieties (95110 days).

Also important is the division of varieties with respect to the content of sugars in kernels at
the phase of harvest ripeness. With reference to their genetic features, they are classified as:
-

normally sweet, with the gene su-1 (sugary),

with increased content of sugars, with the gene se or se+ (sugary enhanced),
very sweet, with the gene sh-2(shrunken 2).

Variety selection is an important consideration in sweet corn production and includes

factors such as sweetness, days to maturity, seed color, size, yield potential, and tolerance to
pests. The Cooperative Extension Service can provide a list of varieties recommended for
each region.
Genotype

Sweetness

Normal sugary (su)

Moderately sweet
Sweeter than (su)
less sweet than
(sh2)

Sugary enhanced
(se), (se+)
Super sweet or
shrunken (sh2)

Very sweet

Conversion of
sugars to starch
Rapid

(sh2) vaieties

Not as rapid as (su)

(sh2) vaieties

Very slow

(su), (se), (sh +)

vaieties

Isolate form

Table 1. Sweet Corn Genotypes (http://attra.ncat.org/attra-pub/PDF/sweetcorn.pdf)

Modern sweet corn varieties are classified as: "normal sugary" (su); "sugary enhanced" (se)
and (se+); and "shrunken" (sh2), also called "super sweet." These differ in flavor and
tenderness, and in the rate at which starches are converted to sugar. In general, (se) lines
yield the best, followed by (sh2), and finally (su). Cross-pollination of sweet corn with other
kinds of corn or with some other sweet corn genotypes can result in starchy-tasting kernels.
Generally, a minimal isolation distance of 250 feet between those varieties or types is
recommended; 700 feet, however, is preferred for more complete isolation. Table 1
summarizes the general characteristics of sweet corn genotypes, including isolation
requirements. The normally sweet varieties contain 46% of sugars in fresh kernel mass,
those with higher sugar content from 6 to 8%, and the very sweet varieties, sometimes also
called super sweet or extra sweet, from 8 to 12%. Another criterion of division or
classification of cucltivars is the colour of their kernels which can be yellow (the largest
group of varieties), white, yellow-white (bicolor) and red (Wong, 1994).

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2. Uses of sweet corn

Sweet corn kernels can be consumed both as fresh produce and in processed forms. In
practice, most frequently three basic directions of their utilization are distinguished:
-

direct consumption - cobs harvested at milk ripeness of seed, for so-called freshproduce
market;
fruit-and-vegetable processing industry - cobs harvested at late-milt ripens of seed, for
pickles and frozen foods;
industrial processing - cobs harvested at full ripeness of seed, for flour, meal, etc.

3. Sweet corn processing technology

3.1 Harvest of sweet corn cobs
Sweet corn for processing is harvested at a relatively immature stage as compared to field
corn. Processing of corn is used to increase its shelf life but as a consequence, a significant
loss of nutrients may occur via heat degradation or leaching (Scott and Eldridge, 2005).
Sweet corn for processing is picked at different stages of maturity depending on the way
it is to be processed. The corn for freezing is harvested at about the same stage as that for
fresh market, while the corn for whole kernel pack and cream-style is harvested at a
slightly later stage of maturity. For whole kernel canning and freezing, optimum kernel
moisture ranges from 70 to 76%. For cream-style canning corn, optimum kernel moisture
is about 66%. Experience showed that it correlated very closely with the moisture
percentage and with postharvest grade evaluation Olson (2000). There are many reasons
why crops should be harvested at optimal maturity for their specific end uses. An
accurate determination of the sweet corn maturity for harvest can ensure the best possible
crop yield and quality. The optimum moisture for harvesting shrunken sweet corn for
freezing and canning is no less than 76% and no more than 79%. This compares to the
range for standard sweet corn of 70 -72%. Because the shrunken sweet corn loses only
about percent of moisture per 24-hr period at the 76% level as compared to 1% per 24-hr
period for standard sweet corn, the harvest window for shrunken corn harvest for a
processing line and results in fewer bypassed fields due to planting, mistiming, or
weather delay (Marshall and Tracy, 2003). However, according to Warzecha (2003), it is
easier to mechanise the harvest of standard sweet corn than that of shrunken sweet corn.
The standard sweet corn compares to shrunken varieties mature to longer. Sweet corn has
a very short period of optimum harvest maturity, and its quality changes rapidly close to
and following the peak. Ears harvested immature will have a small diameter, a poor cob
fill, and kernels that are watery and lack sweetness. At optimum harvest maturity, the
kernels are plump, sweet, milky, tender, and nearly of maximum sizes. After optimum
harvest maturity has been reached, the eating quality of sweet corn begins to decrease
rapidly, while the husk appearance changes very little. Overmature corn is rather starchy
than sweet, tough, and the kernels are often dented (Motes et al., 2007). However,
according to Kumari et al. (2007), the unfavourable correlation coefficients between the
sugar content and grain weight suggested that it is difficult to obtain high-yielding sweet
corn hybrids of good quality.
Results of sweet corn ear size measured at different harvest date are presented in Table 2.

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Particular
Moisture content (%)
Yield (tha-1)

1st
77.41a
(0.95)
18.64a
(1.15)

Length (cm)
Max. diameter (cm)
Number of kernels per row
(pcs)
Number of kernel rows
(pcs)
Bulk density (kg m-3)

612.21a
(9.12)

Harvest date
2nd
3rd
72.31c
75.62ba
(0.88)
(1.05)
16.31c
17.98ba
(1.21)
(0.98)
22.21 (2.09)
4.94 (0.98)

4th
69.83d
(1.09)
15.88dc
(1.11)

LSD
= 0.05
2.05
1.20
-

28.05 (1.57)

14.72 (1.54)

619.54ba
(8.65)

624.36cb
(10.21)

634.54d
(8.86)

9.36

Numbers in the same line followed by the same letter are not significantly different at p<0.05.

Table 2. The mean values of kernels moisture content, yield ears, ear length, ear diameter,
number of kernels per row, number of kernel rows and bulk density with standard
deviation in parenthesis
The mean size of 100 husked ears measured at a first harvest date are: length 22.212.09 cm
and max. diameter 4.940.98 cm. The yield decreased from 18.64 to 15.88 tha-1, when the
moisture content of kernels decreased from 77.41 to 69.83%. The similar decreasing of
moisture content with increasing harvest maturity has been reported by Wong, (1994).
At all harvest date (moisture contents), an increase of deformation with an increase in
applied forces was observed (Table 3).
Particular
Compression force (N)
Shear force (N)
Puncture force (N)

1st
29.48a
(1.78)
8.21a
(0.28)
9.11a
(0.18)

Harvest date
2nd
3rd
42.71c
35.54ba
(1.32)
(1.54)
12.34cb
10.41ab
(0.41)
(0.32)
ba
12.65
15.28cb
(0.19)
(0.17)

4th
49.56dc
(1.23)
15.21dc
(0.37)
17.23dc
(0.21)

LSD
= 0.05
7.11
3.21
4.56

Numbers in the same line followed by the same letter are not significantly different at p<0.05.

Table 3. The means values of compression, shear and puncture force with standard
deviation in parenthesis
The hull rupture is marked by an audible click, and a sudden decrease of the force occurs.
The point marked by the abrupt force decrease is often called the bio-yield point and the
loading was stopped once this point was reached. The measured parameters were the
rupture force, when the kernel hull undergoes failure during compression, shear and
puncture, the deformation up to the rupture point.

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The force required for the hull rupture increase as the moisture content decreased. At the
moisture content ranging from 77.41 to 69.83% the compression force increased from 29.48
to 49.56 N, the shear force increased from 8.21 to 15.21 N and the penetration force increased
from 9.11 to 17.23 N. Burton (1982) reported that the average puncture tensile strength
forces increased with later harvest date.
During the period when sweet corn ears are suitable for harvesting and kernel moisture
decreases total of sugars decreased from 6.24 to 5.11% and starch increased from 14.49 to
22.19% (Table 4).
Particular

1st

Total sugars (%)

6.24a (0.24)

Starch (%)

14.49a (0.22)

Harvest date
2nd
5.92ba
(0.21)
16.21ba
(0.24)

3rd
5.54c
(0.19)
18.70c
(0.21)

4th
5.11d
(0.18)
22.19d
(0.23)

LSD
= 0.05
0.41
2.24

Numbers in the same line followed by the same letter are not significantly different at p<0.05.

Table 4. The means values of total sugars and starch level with standard deviation in
parenthesis
It was observed that the harvest date affect total sugars and starch level. The mean values of
total sugars and starch only between 1st and 2nd harvest date werent significantly different.
(Table 2). Similar trend have been reported by Suk and Sang (1999).
The processing recovery and corn cut yield increased (from 41.14 to 50.02%, and 7.67 to 7.94
tha-1, respectively) for different harvest date (Table 5).
Particular
Processing recovery (%)
Corn cut yield (tha-1)
Bulk density (kg m-3)

1st
41.14a
(3.48)
7.67a
(0.13)
585.51a
(9.42)

Harvest date
2nd
3rd
48.25cb
43.13ba
(4.11)
(3.98)
7.86cb
7.75ba
(0.11)
(0.10)
592.31ba
601.74cb
(9.12)
(9.06)

4th
50.02dc
(4.02)
7.94dc
(0.12)
609.11dc
(9.21)

LSD
= 0.05
6.86
0.13
12.36

Numbers in the same line followed by the same letter are not significantly different at p<0.05.

Table 5. The means values of processing recovery, corn cut yield and bulk density with
standard deviation in parenthesis
The explanation for these increase of recovery could be found in the decline of moisture
level and increases of starch content. Michalsky (1986) found that lower average moisture
content and higher starch level make easy to mechanical cutting the kernel off the cob and
reduce losses of kernel flesh. This is why the sweet corn for whole kernel canning is harvest
at lower moisture content than for frozen style corn. Although corn cut yield was the
highest at the lowest moisture content (69.83%) it was observed that some single kernels
begun to wrinkle. A similar result was reported by Olson (2000), who found that that the

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highest quality cut corn from most of the standard sweet corn hybrids would be obtained at
a kernel moisture level of 72 to 73%. At 74 to 75% moisture, the flavor and taste were good
but kernel size and uniformity, color, and cut-corn yield of the standard sweet hybrids
might be below par. At 70 to 71%, a critical dividing point, yield was higher but the cut corn
would appear to be older (large; darker yellow kernels) and might be tougher.
3.2 Kernels removing from the cobs
3.2.1 Cutting method for removal of kernels from raw sweet corn cobs
The food processing industry currently applies machines utilizing rotary cutter heads for
severing corn kernels (Kessler and Harry, 1998) (Fig. 2).

2
3

Fig. 2. Schematic of sweet corn kernel cutter: 1 knife head, 2 feeder of cobs, 3 ,rollers of
copying system, 4 removing rollers of cob cores (Robertson and Farkas, 1982).
The action of separating sweet corn kernels from the cob for consumption purposes is
performed with the use of special cutters, the operation of which is described by many
authors. To obtain kernels of high quality, the working elements of such machines should be
carefully adjusted so that all the kernels are cut off as close to the cob core as possible, but
without cutting off the cob husks whose presence among the kernels acquired worsens the
quality of the product. Until recently it was recommended that kernels should be cut off at
2/3 of their length with the kernel germs remaining on the cob core, as predominant in corn
production were varieties with long cob husks. New hybrid varieties of corn are free of that
defect, and to increase the amount of material acquired cutter knifes are set to the maximum
length of kernels detached. Care must be taken that the cut through the kernel be smooth,
without tearing the seed cover, and set so that no thick cob husks are among the kernels
detached. This requires frequent sharpening of the cutter knives. Adjustment of the working
elements of the kernel cutter should be made suitably to changes in the dimensions and
properties of the material processed. Corn cobs should oriented with their narrower end
towards the cutter head, as in that position the cutter knives adapt better to correct
detachment of kernels. During kernel cutter operation, it is necessary to systematically check

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all the moving elements of the machine, and to clean and lubricate as required. This has an
immense effect on the quality of kernels detached, as with the cutter head dirty the positions
of cutter knives take longer to adjust to the changing cob diameter, and them may result in
increased amount of incorrectly cut off kernels.
The mechanical removal of sweet corn kernels from the cob by cutting leads to waste, loss of
nutritional value, and loss of yield (Hanna et al., 1988). This means that it is not possible to
obtain all the kernels of corn. The cutting operation severs the upper part of the kernel from
the lower part, which remains on the cob. Thus, the hull of the kernel is broken open and a
part of each kernel is wasted (approximately 20% remains on the cob), including much or
the entire germ of the kernel. Furthermore, during subsequent wet-processing, including
washing and blanching of the severed kernels, some of the corn meat is leached from its
pouch and lost (Kunicki, 2003). However the proportion of cut-off kernels is strictly related
to the moisture product processing characteristics. The successful detachment of sweet corn
kernels as intact kernels promises large advantages in terms of yield and effluent over cut
kernels during processing, but it does require low strength kernel attachment to the cob. The
study by Niedzika and Szymanek (2004) showed that blanching prior to the cutting
process, instead of blanching after kernel cutting, resulted in a 12% increase in yield of cut
kernels and quality. However, a similar study by Trongpanich et. al. (2002) did not show a
statistically significant difference (0.05), while Michalsky (1986) reported that by delaying
the time of harvest until the moisture content decreased, it is possible to increase the
detached part of the kernel.
The studies of Szymanek (2011) showed that the cut kernel yield increased with the increase
in cutter head angular speed. The change of speed from 167.5 to 293.2 rad s-1 increased
approximately 51% for the Jubilee variety, 29% for the Boston variety, and 54% for the Spirit
variety. The differences recorded between the varieties were statistically significant. An
increase of cutter head angular speed from 167.5 up to 293.2 rad s-1 resulted in a statistically
significant decrease of inferior kernel share. The highest reduction in inferior kernels in the
investigated speed range was obtained for the Spirit variety, at about 64%, whereas the
lowest was for Boston, at about 44%. An increase in the amount of kernels cut, along with a
change of a cutter head angular speed, also decreased sugar content loss. The most
substantial decline in sugar losses within the studied range of cutter head speed was
observed for the Jubilee variety, with about 48%, while the lowest for Spirit and Boston was
about 33%. A change in a cutter head angular speed generally resulted in a statistically
significant effect on the differences in sugar content. Increasing cutter head angular speed in
the range of 167.5 to 293.2 rad s-1 induced a decrease in kernel mass losses subject to the
plant variety. The changes were in the range from 51 to 28%. Spirit variety had the highest
reduction in sugar losses.
The losses occurring in the production process have negative effects not only in economical
terms, but also pose considerable environmental pollution problems. The loss of kernels
could, however, be reduced by means of the respective choice of sweet corn varieties.
Robertson et al. (1980) think that solutions to this problem are being developed by food
engineers and plant breeders by modifying the mechanical separation method and by
modifying the raw product processing characteristics. However, claims that reduction of the

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kernel moisture could be achieved by delaying the cob harvesting dates, which, in turn,
reduces loss during the kernel cutting process. In addition, blanching the cobs prior to
attempting the cutting process (Stewart et al., 1997) and selecting the optimum operation
parameters of the kernel cutter devices also reduces loss (Niedzika and Szymanek,
2006). The method proposed by Robertson and Farkas (1982), whereby the cobs are halved
along their length and the kernel is subsequently detached on reciprocally moving
conveyor belts can practically reduce kernel loss to almost zero. However, this method is
less efficient and consumes too much energy and has not so far been applied on industrial
scale. In recent years, the growing concern about applying freezing methods, including
cryo-liquids, in the food processing industry has also been reflected by the growth in
manufacturing of frozen products , including sweet corn (frozen cobs or kernel). In highly
technologically advanced countries, about 30% (20% in Poland) of the production output
of sweet corn is designated for freezing and about 40% for canned food (60% in Poland)
(Waligra, 2006). Freezing in boiling liquids means very high convective heat-transfer
coefficients, considerable temperatures and consequently very short freezing times.
Unlike in classic (slow) freezing, the cryo-liquid freezing method results in a high quality
of the product processed. Kernel frozen in temperatures of 40C fit long-term storage
requirements without any significant change in taste and technological properties
(Matheus et al., 2004). The growing demand for frozen products brings about a need to
develop technologies that can provide storage of fresh vegetables and fruit, while their
physical properties undergo no essential changes.
3.2.2 Shelling method for removal of kernels from frozen sweet corn cobs
In the shelling method for removal of kernels from frozen sweet corn cob the corn cobs prior
to shelling are subjecting to blanching and freezing by spraying in liquid nitrogen.
110
Kernel separation rate (%)

Mean

Standard deviation

100

0.95% Confidence interval

c
dc

ecd

90
b
80
70
60

50
2

6
Time (min)

Numbers in the same letter are not significantly different at p<0.05.

Fig. 3. The effect of freezing time on kernels separation rate

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The mean values of kernel separation rate of cobs for 2, 4, 6, 8 and 10 minutes freezing time
were: 55.1%; 79.9%, 96.7%, 95.8% and 97.0% respectively (Fig. 3).
In the range from 2 to 6 minutes freezing time we can observe the statistically significant
increases of kernels separation rate and then from 6 to 10 minutes the not significant
changes of kernels separation rate. This might be due to lack of uniformity in kernels
freezing which results in different kernels hardness and not complete kernels removal.
The advantage of this method is the reduction of waste and increased yield of corn.
During the analyses of kernels separation (Szymanek, 2011), it was confirmed that 86.3%
of intact kernels removed after 2 and 4 min of freezing contained adhering cob related
tissue, and 13.7% of kernels were without such tissue. However, for intact kernel freezing
for 6, 8 and 10 min, the relations were opposite and amounted to, respectively, 8.9 and
91.1%. This means that the optimal freezing time influences not only the quantity but also
the quality.
Robertson et al. (1980), in a comparison between cut and intact kernels, found that intact
kernels have more adhering cob-related tissues which is perceived as a defect of intact
kernels
In the range from 2 to 10 minutes were observed the decrease of kernels damage from 7.3 to
3.9%. The share of damaged kernels showed the same tendency as changes of kernels
separate rate. The proportions of damaged kernels for 6, 8 and 10 minutes freezing time
although different in value are not significantly different. Decreasing of kernels damages
together with lengthen of freezing time might be due to increasing of hardness of whole
kernels which results in kernels being more resistant to mechanical action of shelling unit.
The mechanism of damages formation can be compared to threshing dried cob. Nguyen
(1986) reported that when shelling dried cob, only the linkage between kernel and corn cob
is broken When threshing fresh cob, we have to break down two linkages: kernel - corn cob
and kernel - kernel. This causes a considerable amount of broken kernels. Similar situation
might occur when freezing kernels.

4. Summary
The use value of sweet corn, resulting from its high nutritional values, taste qualities, and
extensive possibilities of application, fully justifies the sense of increasing the area of its
variation. The search for new and more efficient methods of harvest at simultaneous
assurance of favorable economic effects and high quality requirements for the sweet corn
cobs and kernel produced, become a necessity. Sweet corn cobs harvested for the processing
industry are subjected to machining consisting in the kernel cutting off from cob core. Since
a considerable part of sugars is cumulated in the lower part of the kernel, it is recommended
to cut kernels off cobs as close to the core as possible. The irregular shape of kernels and
their low content of dry mass (approx. 27%) are the reason for frequent mechanical damage
to kernels. Kernels, especially those located at extreme parts of the cob, differ in their size
and hardness. Also the shapes of cobs (cylindrical or tapered) and their variable size
(variety-related) make the detachment of kernels more difficult. Hence the process of kernel
cutting off from cob cores is a major problem for the processing industry.

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The study has shown that sweet corn kernels can be removed from the cob by using shelling
method when there are first subject to rapid freezing by spraying liquid nitrogen. The
freezing time of 2, 4 and 6 minutes affects significantly the increase of hardness and
separation rate and decrease of damage and kernels losses. Starting from 6 minutes freezing
time, the time of 8 and 10 minutes had no significance effect on average values of analysed
parameters. The visual observation of kernels showed that for freezing time of 2 and 4
minutes 86.3% of intact kernels had and 13.7% had not adhering tissue. In contrast, after 6, 8
and 10 minutes freezing time only 8.9% of intact kernels had and about 91.1% had not
adhering tissue.

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Trends in Vital Food and Control Engineering

Edited by Prof. Ayman Amer Eissa

ISBN 978-953-51-0449-0
Hard cover, 290 pages
Publisher InTech

Published online 05, April, 2012

Published in print edition April, 2012

This book is an example of a successful addition to the literature of bioengineering and processing control
within the scientific world. The book is divided into twelve chapters covering: selected topics in food
engineering, advances in food process engineering, food irradiation, food safety and quality, machine vision,
control systems and economics processing. All chapters have been written by renowned professionals working
in food engineering and related disciplines.

How to reference

In order to correctly reference this scholarly work, feel free to copy and paste the following:
Mariusz Szymanek (2012). Processing of Sweet Corn, Trends in Vital Food and Control Engineering, Prof.
Ayman Amer Eissa (Ed.), ISBN: 978-953-51-0449-0, InTech, Available from:
http://www.intechopen.com/books/trends-in-vital-food-and-control-engineering/processing-of-sweet-corn

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